A combustion retarding material and uses thereof

ABSTRACT

A combustion retarding material including a combustion retarding salt and an amorphous solid material as well as consumables having the combustion retarding material, and non-combustible aerosol provision systems having such consumables. Methods for manufacturing the combustion retarding material and the use of a combustion retarding salt and an amorphous material to retard combustion.

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No.PCT/GB2021/05216, filed Aug. 20, 2021, which claims priority from GBApplication 2013121.5, filed Aug. 21, 2020 and GB Application No.2109079.0, filed Jun. 24, 2021, each of which hereby fully incorporatedherein by reference.

FIELD

The invention relates to a combustion retarding material comprising acombustion retarding salt and an amorphous solid material. It alsorelates to consumables comprising the combustion retarding material, andnon-combustible aerosol provision systems comprising such consumables.The invention further relates method for manufacturing the combustionretarding material and the use of a combustion retarding salt and anamorphous material to retard combustion.

BACKGROUND

Smoking articles such as cigarettes, cigars and the like burn tobaccoduring use to create tobacco smoke. Attempts have been made to providealternatives to these articles by creating products that releasecompounds without combusting. Examples of such products are so-called“heat not burn” products or tobacco heating devices or products, whichrelease compounds by heating, but not burning, smokeable material.

SUMMARY

According to a first aspect of the invention, there is provided acombustion retarding material comprising a combustion retarding salt andan amorphous solid material.

In some embodiments, the combustion retarding salt is an alkali metalsalt, optionally selected from the group consisting of: sodium chloride,potassium chloride, sodium bromide, potassium bromide, and combinationsthereof.

In some embodiments, the combustion retarding salt is incorporated inthe amorphous solid material.

In some embodiments, the combustion retarding salt is applied to theamorphous solid material.

In some embodiments, the combustion retarding material comprises fromabout 3 wt to about 60 wt % of the combustion retarding salt (dry weightbasis).

According to a second aspect of the invention, there is provided aconsumable comprising a combustion retarding material according to thefirst aspect.

In some embodiments, the consumable further comprises anaerosol-generating material.

In some embodiments, the combustion retarding material at leastpartially surrounds the aerosol-generating material.

In some embodiments, the consumable further comprises a wrapper.

In some embodiments, the combustion retarding material is distributedwithin the aerosol-generating material.

In some embodiments, the aerosol-generating material comprises tobaccomaterial. In some embodiments, the tobacco material is cut rag tobacco.

In some embodiments, the consumable comprises a binder.

In some embodiments, the consumable is rod shaped.

According to a third aspect of the invention, there is provided anon-combustible aerosol provision system comprising a consumableaccording to the second aspect.

According to a fourth aspect of the invention, there is provided amethod for manufacturing the material according to the first aspect,wherein the combustion retarding salt is incorporated into or added tothe amorphous solid material.

In some embodiments, a solution or suspension comprising the combustionretarding salt is applied to the amorphous solid material.

In some embodiments, the combustion retarding salt is added during themanufacture of the amorphous solid material.

According to a fifth aspect of the invention, there is provided use ofthe material according to the first aspect for retarding combustion of aconsumable for use in a non-combustible aerosol provision system.

BRIEF DESCRIPTION OF THE DRAWING

Embodiments of the invention will now be described, by way of exampleonly, with reference to accompanying drawings, in which:

FIG. 1 is a side-on cross sectional view of a first embodiment of aconsumable for use with a non-combustible aerosol provision devicecomprising the combustion retarding material;

FIG. 2 is a side-on cross sectional view of a second embodiment of aconsumable for use with a non-combustible aerosol provision devicecomprising the combustion retarding material;

FIG. 3 is a perspective illustration of a non-combustible aerosolprovision device for generating aerosol from the aerosol-generatingmaterial of the consumables of FIG. 1 or FIG. 2 .

DETAILED DESCRIPTION

The present invention relates to a combustion retarding materialcomprising at least one combustion retarding salt and an amorphous solidmaterial.

Combustion Retarding Salt

The salt used herein is a chemical compound consisting of an ionicassembly of cation and anions. The salts used herein are those whoseanion and/or whose cation may be effective in retarding combustion. Insome embodiments, the salt is an inorganic salt.

In some embodiments, the salt is a halide salt, i.e. has a halide anion.In some embodiments, the salt is a chloride salt or a bromide salt. Thepresence of high concentrations of chloride or bromide has been shown toretard combustion, as discussed further below.

In some embodiments, the salt may be an alkali metal salt, i.e. has analkali metal cation. In some embodiments, the salt has an alkaline earthmetal cation. In some embodiments, the salt has a zinc cation or an ironcation, such as a ferric or ferrous cation. In some embodiments, thesalt has an ammonium cation or a phosphonium cation.

In some embodiments, the salt may be an alkali metal halide, such assodium chloride or potassium chloride. The salt may be an alkaline earthmetal halide, such as magnesium chloride, calcium chloride. The salt maybe another metal halide, such as zinc chloride or sodium bromide.

In some embodiments, the salt has a carboxylate anion. For example, thesalt may be an alkali metal carboxylate, such as potassium citrate,potassium succinate, potassium malate, potassium acetate, potassiumtartrate, potassium oxalate, sodium citrate, sodium succinate, sodiumacetate, or sodium malate.

In other embodiments, the salt has an anion selected from: borate,carbonate, phosphate, sulphate or sulphamate.

Factors that may influence the selection of salt will include, forexample, melting point, which will preferably be at least 450° C. Insome embodiments, the salt is soluble in water. In some embodiments, thesalt is selected to provide a desired pH to the material it is added to.In some embodiments, the salt will not significantly change the pH ofthe material

In some embodiments, sodium chloride (NaCl) is the salt used. It hasbeen demonstrated that amorphous solid material with a high chloridecontent is difficult to combust. Further, sodium chloride is neutral,highly soluble and does not affect pH of the amorphous solid material.

The combustion retarding salt may be one salt or a combination of anynumber of salts disclosed herein or known in the art, and is referred toas “combustion retarding salt” herein. The combustion retarding salt(s)may be advantageously selected to give the combustion retarding materialdesired characteristics.

In some embodiments, the combustion retarding salt selected may have oneor more advantageous properties, such as: inertness, solubility in aprecursor liquid, solubility or distribution in the amorphous solid orprecursor material to the amorphous solid, density or other propertiesknown in the art.

In some embodiments, the combustion retarding salt comprises, consistsessentially of, or consists of sodium chloride, potassium chloride,sodium bromide and/or potassium bromide.

Depending on the combustion retarding or other physical propertiesdesired, the components of the salt may be in free base form, salt form,or as a complex, or as a solvate. The combustion retarding salt may beof any density and any crystalline structure.

In some embodiments, the combustion retarding salt is incorporated intoor added to the amorphous solid material dissolved in a solvent orliquid carrier. In some embodiments, the combustion retarding salt issuspended in a liquid carrier. The solvent or liquid carrier may be anaqueous or organic liquid, and may be polar or non-polar depending onits suitable application.

The liquid carrier or precursor solvent may be advantageously selectedto be readily removed during the manufacture of the combustion retardingmaterial to leave the combustion retarding salt in or on the amorphoussolid material.

In some embodiments, the liquid carrier is a mixture of liquids,including aqueous liquid (water) and non-aqueous liquid (e.g. glycerol).Upon removal of the water following application of the salt, theglycerol will be retained in the amorphous solid material, where itoffers flexibility and assists in aerosol formation upon heating.

The Amorphous Solid Material

The combustion retarding material comprises an “amorphous solidmaterial”, which may alternatively be referred to as a “monolithicsolid” (i.e. non-fibrous). In some embodiments, the amorphous solidmaterial may be a dried gel. The amorphous solid is a solid materialthat may retain some fluid, such as liquid, within it.

The amorphous solid material may comprise from about 0.1 wt %, 0.5 wt %,1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %,50 wt %, 45 wt %, 40 wt % or 35 wt % of a gelling agent (all calculatedon a dry weight basis). For example, the amorphous solid may comprise1-50 wt %, 5-45 wt %, 10-40 wt % or 20-35 wt % of a gelling agent. Insome embodiments, the gelling agent comprises a hydrocolloid.

In some embodiments, the gelling agent comprises one or more compoundsselected from the group comprising alginates, pectins, starches (andderivatives), celluloses (and derivatives), gums, silica or siliconescompounds, clays, polyvinyl alcohol and combinations thereof. Forexample, in some embodiments, the gelling agent comprises one or more ofalginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose,carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan,agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin andpolyvinyl alcohol. In some cases, the gelling agent comprises alginateand/or pectin, and may be combined with a setting agent (such as acalcium source) during formation of the amorphous solid. In some cases,the amorphous solid may comprise a calcium-crosslinked alginate and/or acalcium-crosslinked pectin.

In some embodiments, the gelling agent comprises alginate. In apreferred embodiment, the alginate is present in the amorphous solid inan amount of from 1-30 wt % of the amorphous solid (calculated on a dryweight basis). In some embodiments, alginate is the only gelling agentpresent in the amorphous solid. In other embodiments, the gelling agentcomprises alginate and at least one further gelling agent, such aspectin.

In some embodiments the combustion retarding material may comprise anamorphous solid which may include gelling agent comprising carrageenan.

Suitably, the amorphous solid may comprise from about 0.1 wt %, 0.5 wt%, 1 wt %, 3 wt %, 5 wt %, 7 wt %, 10 wt %, 15 wt %, 20 wt %, 25 wt %,30 wt %, 35 wt % or 40% to about 75 wt %, 70 wt %, 65 wt %, 60 wt %, 55wt % or 50 wt % of an aerosol-former material (all calculated on a dryweight basis). For example, the amorphous solid may comprise 5-10 wt %,20-70 wt %, 40-60 wt % or 50-60 wt % of an aerosol-former material.

As used herein, the aerosol-former material may comprise one or more ofglycerine, glycerol, propylene glycol, diethylene glycol, triethyleneglycol, tetraethylene glycol, 1,3-butylene glycol, erythritol,meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate,triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzylphenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid,and propylene carbonate.

In some cases, the aerosol-former material comprises one or morecompound selected from erythritol, propylene glycol, glycerol, vegetableglycerine (VG), triacetin, sorbitol and xylitol. In some cases, theaerosol-former material comprises, consists essentially of or consistsof glycerol.

The aerosol-former material may act as a plasticizer. For example, theamorphous solid material may comprise 0.5-40 wt %, 3-35 wt % or 10-25 wt% of an aerosol-former material. In some cases, the aerosol-formermaterial comprises one or more compound selected from erythritol,propylene glycol, glycerol, triacetin, sorbitol and xylitol. In somecases, the aerosol-former material comprises, consists essentially of orconsists of glycerol. The inventors have established that if the contentof the plasticizer is too high, the amorphous solid material may absorbwater resulting in a material that does not create an appropriateconsumption experience in use. The inventors have established that ifthe plasticizer content is too low, the amorphous solid material may bebrittle and easily broken. The plasticizer content specified hereinprovides an amorphous solid flexibility which allows the amorphous solidsheet to be wound onto a bobbin, which is useful in manufacture ofaerosol-generating articles.

In some embodiments, the amorphous solid material is a hydrogel andcomprises less than about 20 wt % of water calculated on a wet weightbasis. In some cases, the hydrogel may comprise less than about 15 wt %,12 wt % or to wt % of water calculated on a wet weight basis. In somecases, the hydrogel may comprise at least about 1 wt %, 2 wt % or atleast about 5 wt % of water (WWB).

The Combustion Retarding Material

In some embodiments, the combustion retarding material comprises acombination of an amorphous solid material and a combustion retardingsalt, as discussed herein.

In some embodiments, the proportion of combustion retarding salt in thecombustion retarding material may be advantageously selected for itscombustion retardant properties. Suitably, the combustion retardingmaterial may comprise from about 3 wt %, 15 wt %, 20 wt %, 25 wt %, 30wt %, 35 wt %, 40 wt %, 45 wt %, or from about 50 wt % to about 90 wt %,85 wt %, 80 wt %, 75 wt %, 70 wt %, 65 wt % or to about 60 wt % of thecombustion retarding salt (all calculated on a dry weight basis).

In some embodiments, the combustion retarding salt is incorporated intothe amorphous solid material. This means that the combustion retardingsalt is included within the amorphous solid composition. For example,during the preparation of the amorphous solid material, a liquidprecursor of the amorphous solid material is mixed with combustionretarding salt. This distributes the combustion retarding saltthroughout the resultant amorphous solid material. In some embodiments,the distribution of the combustion retarding salt is even throughout theamorphous solid and this may be advantageous as the combustion retardingeffect is effective across all of the material. The combustion retardingsalt may be added in the form of a solution or suspension.Alternatively, the combustion retarding salt may be added to the liquidprecursor in solid form, for example in particulate form, such as apowder.

In other embodiments, the combustion retarding salt is added or appliedto the amorphous solid material. For example, once the amorphous solidmaterial has been prepared, a solution or suspension comprising thecombustion retarding salt is applied to the surface of the amorphoussolid material, to deposit the combustion retarding salt on the surfaceof the amorphous solid material.

In some embodiments, the amorphous solid material is contacted with asolution or a suspension comprising the combustion retarding salt. Thistechnique may be used to form a coating of salt on the surface of theamorphous material. This technique may be repeated multiple times toform one or more layers of the combustion retarding salt. In someembodiments, different combustion retarding salts may be incorporated inthe one or more coatings and/or in the amorphous solid material. Thismay provide a specific combustion-retarding profile.

In some embodiments, a solution or suspension of the combustionretarding salt may be sprayed directly onto the amorphous solid. This isadvantageous because the layer of the inorganic solid may be evenlydistributed over the amorphous solid. This process may also be repeatedto provide a desired thickness of the layer of combustion retardingsalt, which is a further advantage. The layers of the combustionretarding salt may comprise the same salt or different salts.Additionally, the proportion of the combustion retarding salt in thecarrier liquid or solvent may be altered to provide a layer on theamorphous solid material with desired properties. In such embodiments,the proportion of the combustion retarding salt in the solvent orcarrier liquid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %,20 wt % or 25 wt % to about 60 wt %, 50 wt %, 45 wt %, 40 wt % or 35 wt% of the combustion retarding salt (all calculated on a dry weightbasis).

In some embodiments, the combustion retarding material comprises:

-   -   about 1 to about 50 wt % of a gelling agent;    -   about 0.1 to about 50 wt % of an aerosol-former agent; and    -   about 3 to about 90 wt % of an combustion retarding salt;    -   wherein these weights are calculated on a dry weight basis.

In particular exemplary embodiments, the combustion retarding materialcomprises:

-   -   about 20 to about 30 wt % of a gelling agent;    -   about 20 to about 30 wt % of an aerosol-former agent; and    -   about 50 to about 60 wt % of an combustion retarding salt;    -   wherein these weights are calculated on a dry weight basis.

In another example, the combustion retarding material is formed from aslurry comprising:

-   -   43 g alginate (2.7%)    -   100 g sodium chloride (6.3%)    -   50 g glycerol (3.1%)    -   1400 ml water (87.9%).

Once this slurry has been dried, the composition of the combustionretarding material will be as follows: alginate (22.3%); sodium chloride(52.1%); and 50 g glycerol (25.6%).

In some cases, the combustion retarding material may consist essentiallyof, or consist of a combustion retarding salt, a gelling agent, anaerosol-former agent and water.

The inventors have advantageously found that an improved article may beproduced comprising a combustion retarding material comprising acombustion retarding salt and an amorphous solid, wherein the materialproperties (e.g. density) and specification (e.g. thickness, length, andcut width) fall within the ranges set out herein.

In some cases, the combustion retarding material may have a thickness ofabout 0.015 mm to about 1.5 mm, suitably about 0.05 mm to about 1.5 mmor 0.05 mm to about 1 mm. Suitably, the thickness may be in the range ofabout 0.1 mm or 0.15 mm to about 1 mm, 0.5 mm or 0.3 mm. The combustionretarding material may comprise more than one layer, and the thicknessdescribed herein refers to the aggregate thickness of those layers.

In some embodiments in which the combustion retarding material includesthe combustion retarding salt as a coating on the amorphous solid, thecoating layer of combustion retarding salt may have a thickness of about0.01 mm to about 0.1 mm. The combustion retarding salt coating maycomprise more than one layer, and the thickness described herein refersto the aggregate thickness of those layers.

The thickness of the material or layers discussed herein may be measuredusing a microscope such as a scanning electron microscope (SEM), asknown to those skilled in the art, or any other suitable technique knownto those skilled in the art.

The inventors have established that if the combustion retarding materialis too thick, then heating efficiency can be compromised. This canadversely affect power consumption in use, for instance the powerconsumption for release of flavor from the amorphous solid. Conversely,if the combustion retarding material is too thin, it can be difficult tomanufacture and handle; a very thin material can be harder to cast andmay be fragile, compromising aerosol formation in use. In some cases, anindividual strip or piece of combustion retarding material has a minimumthickness over its area of about 0.015 mm. In some cases, an individualstrip or piece of the amorphous solid has a minimum thickness over itsarea of about 0.05 mm or about 0.1 mm. In some cases, an individualstrip or piece of the amorphous solid has a maximum thickness over itsarea of about 1.0 mm. In some cases, an individual strip or piece of thecombustion retarding material has a maximum thickness over its area ofabout 0.5 mm or about 0.3 mm.

For the avoidance of doubt, where reference is made herein to areadensity, this refers to an average area density calculated for a givenstrip, piece or sheet of combustion retarding material, the area densitycalculated by measuring the surface area and weight of the given strip,piece or sheet of combustion retarding material.

In some cases, the combustion retarding material thickness may vary byno more than 25%, 20%, 15%, 10%, 5% or 1% across its area.

In some embodiments in which the combustion retarding material is insheet form, the sheet may have any suitable area density, such as fromabout 30 g/m² to about 150 g/m². In some cases, the sheet may have amass per unit area of about 55 g/m² to about 135 g/m², or about 80 toabout 120 g/m², or from about 70 to about 110 g/m², or particularly fromabout 90 to about 110 g/m², or suitably about 100 g/m². Such areadensities may be particularly suitable where the combustion retardingmaterial is included in an aerosol-generating article as a shreddedsheet (described further herein).

In some cases, the sheet may have a mass per unit area of about 30 to 70g/m², 40 to 60 g/m², or 25 to 60 g/m² and may be used to wrap anaerosolisable material such as tobacco.

The density of the combustion retarding material has an impact on thespeed at which heat conducts through the material, with lower densities,for instance those below 700 mg/cc, conducting heat more slowly throughthe material, and therefore enabling a more sustained release ofaerosol. The density of the combustion retarding salt also has an impacton the speed of heat conductions, as well as the aforementionedcombustibility of the consumable.

In some examples, such as where the combustion retarding material doesnot comprise a filler, the combustion retarding material may have atensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, orabout 250 N/m. Such tensile strengths may be particularly suitable forembodiments wherein combustion retarding material is formed as a sheetand then shredded and incorporated into the consumable.

In some embodiments, such as where the combustion retarding material isused in sheet form, a filler is included to increase the tensilestrength. In some embodiments, the combustion retarding material mayhave a tensile strength of at least about 1500 or at least about 2000N/m and/or up to about 5000 N/m. In some embodiments, the tensilestrength may be from about 3000 to about 4000 N/m. Such tensilestrengths may be particularly suitable for embodiments whereincombustion retarding material is incorporated into a consumable in sheetform, for example as a wrapper.

In some embodiments, the combustion retarding material comprises anamorphous solid which is a hydrogel and comprises less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogelmay comprise less than about 15 wt %, 12 wt % or 10 wt % of watercalculated on a wet weight basis. In some cases, the hydrogel maycomprise at least about 1 wt %, 2 wt % or at least about 5 wt % ofwater.

Additional Components of the Combustion Retarding Material

In some embodiments, the combustion retarding material may comprise ofadditional components, which are described herein. The additionalcomponents may be included in any part of the combustion retardingmaterial. In some embodiments the additional components included in theamorphous solid material and so are distributed within the combustionretarding material.

In some embodiments, the combustion retarding material comprises one ormore other functional materials, which may comprise one or more of pHregulators, coloring agents, preservatives, binders, fillers,stabilizers, and/or antioxidants.

In some embodiments, the combustion retarding material comprises aflavor. The combustion retarding material therefore has the advantage ofpreventing the combustion of the flavorant and delivering a desiredtaste.

In some embodiments, the combustion retarding material may comprise upto about 80 wt %, 70 wt %, 60 wt %, 55 wt %, 50 wt % or 45 wt % of aflavor. In some cases, the combustion retarding material may comprise atleast about 0.1 wt %, 1 wt %, 10 wt %, 20 wt %, 30 wt %, 35 wt % or 40wt % of a flavor (all calculated on a dry weight basis).

For example, the combustion retarding material may comprise 1-80 wt %,10-80 wt %, 20-70 wt %, 30-60 wt %, 35-55 wt % or 30-45 wt % of aflavor. In some cases, the flavor comprises, consists essentially of orconsists of menthol.

In some embodiments, the flavorant is included in the aerosol-generatingmaterial. Flavor provided in the amorphous solid material may be morestably retained, resulting in a more consistent flavor profile betweenconsumables as disclosed herein.

As used herein, the terms “flavor” and “flavorant” refer to materialswhich, where local regulations permit, may be used to create a desiredtaste, aroma or other somatosensorial sensation in a product for adultconsumers. They may include naturally occurring flavor materials,botanicals, extracts of botanicals, synthetically obtained materials, orcombinations thereof (e.g., tobacco, cannabis, licorice (liquorice),hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile,fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed(anise), cinnamon, turmeric, Indian spices, Asian spices, herb,wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange,mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape,durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits,Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint,peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg,sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honeyessence, rose oil, vanilla, lemon oil, orange oil, orange blossom,cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage,fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil fromany species of the genus Mentha, eucalyptus, star anise, coca,lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate,orange skin, rose, tea such as green tea or black tea, thyme, juniper,elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary,saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle,cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm,lemon basil, chive, carvi, verbena, tarragon, limonene, thymol,camphene), flavor enhancers, bitterness receptor site blockers,sensorial receptor site activators or stimulators, sugars and/or sugarsubstitutes (e.g., sucralose, acesulfame potassium, aspartame,saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol,or mannitol), and other additives such as charcoal, chlorophyll,minerals, botanicals, or breath freshening agents. They may beimitation, synthetic or natural ingredients or blends thereof. They maybe in any suitable form, for example, liquid such as an oil, solid suchas a powder, or gas.

In some embodiments, the flavor comprises menthol, spearmint and/orpeppermint. In some embodiments, the flavor comprises flavor componentsof cucumber, blueberry, citrus fruits and/or redberry. In someembodiments, the flavor comprises eugenol. In some embodiments, theflavor comprises flavor components extracted from tobacco. In someembodiments, the flavor comprises flavor components extracted fromcannabis.

In some embodiments, the flavor may comprise a sensate, which isintended to achieve a somatosensorial sensation which are usuallychemically induced and perceived by the stimulation of the fifth cranialnerve (trigeminal nerve), in addition to or in place of aroma or tastenerves, and these may include agents providing heating, cooling,tingling, numbing effect. A suitable heat effect agent may be, but isnot limited to, vanillyl ethyl ether and a suitable cooling agent maybe, but not limited to eucolyptol, WS-3.

The amorphous solid may be made from a gel, and this gel mayadditionally comprise a solvent, included at 0.1-50 wt %. However, theinventors have established that the inclusion of a solvent in which theflavor is soluble may reduce the gel stability and the flavor maycrystallize out of the gel. As such, in some cases, the gel does notinclude a solvent in which the flavor is soluble. In some embodiments,solvent may be removed by evaporation prior to the inclusion of aflavor.

In some cases, the combustion retarding material may additionallycomprise an emulsifying agent, which emulsified molten flavor duringmanufacture. For example, the combustion retarding material may comprisefrom about 5 wt % to about 15 wt % of an emulsifying agent (calculatedon a dry weight basis), suitably about 10 wt %. The emulsifying agentmay comprise acacia gum (gum arabic) or guar gum.

In some embodiments, the emulsifying agent is included in the amorphoussolid material.

In some embodiments, and where local regulations permit, the combustionretarding material may comprise an active substance. In someembodiments, the combustion retarding material does not comprise anactive substance.

In some embodiments, the active substance is included in the amorphoussolid material.

The active substance as used herein may be a physiologically activematerial, which is a material intended to achieve or enhance aphysiological response. The active substance may for example be selectedfrom nutraceuticals, nootropics, psychoactives. The active substance maybe naturally occurring or synthetically obtained. The active substancemay comprise for example nicotine, caffeine, taurine, theine, vitaminssuch as B6 or B12 or C, melatonin, cannabinoids, or constituents,derivatives, or combinations thereof. The active substance may compriseone or more constituents, derivatives or extracts of tobacco, cannabisor another botanical.

In some embodiments, the active substance comprises nicotine. In someembodiments, the active substance comprises caffeine, melatonin orvitamin B12.

As noted herein, the active substance may comprise one or moreconstituents, derivatives or extracts of cannabis, such as one or morecannabinoids or terpenes.

As noted herein, the active substance may comprise or be derived fromone or more botanicals or constituents, derivatives or extracts thereof.As used herein, the term “botanical” includes any material derived fromplants including, but not limited to, extracts, leaves, bark, fibers,stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.Alternatively, the material may comprise an active compound naturallyexisting in a botanical, obtained synthetically. The material may be inthe form of liquid, gas, solid, powder, dust, crushed particles,granules, pellets, shreds, strips, sheets, or the like. Examplebotanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis,fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax,ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice),matcha, mate, orange skin, papaya, rose, sage, tea such as green tea orblack tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bayleaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary,saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla,wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro,bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace,damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena,tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca,ashwagandha, damiana, guarana, chlorophyll, baobab or any combinationthereof. The mint may be chosen from the following mint varieties:Mentha arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Menthapiperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa,Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata,Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived fromone or more botanicals or constituents, derivatives or extracts thereofand the botanical is tobacco.

In some embodiments, the active substance comprises or derived from oneor more botanicals or constituents, derivatives or extracts thereof andthe botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from oneor more botanicals or constituents, derivatives or extracts thereof andthe botanical is selected from rooibos and fennel.

In some cases, the total content of active substance and/or flavor inthe combustion retarding material may be at least about 0.1 wt %, 1 wt%, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, thetotal content of active substance and/or flavor may be less than about90 wt %, 80 wt %, 70 wt %, 60 wt %, 50 wt % or 40 wt % (all calculatedon a dry weight basis).

In some embodiments and where local regulations permit, the combustionretarding material additionally comprises plant material or tobaccomaterial and/or nicotine.

In some cases, the combustion retarding material may comprise 5-60 wt %(calculated on a dry weight basis) plant material and/or tobaccomaterial and/or nicotine and/or tobacco extract. In some cases, thecombustion retarding material may comprise from about 1 wt %, 5 wt %, 10wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis)plant material and/or tobacco material and/or nicotine and/or tobaccoextract.

In some cases, the combustion retarding material may comprise 5-60 wt %(calculated on a dry weight basis) plant material and/or tobaccomaterial and/or nicotine and/or tobacco extract. In some cases, thecombustion retarding material may comprise from about 1 wt %, 5 wt %, 10wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis)plant material and/or tobacco material and/or nicotine and/or tobaccoextract. In a preferred embodiment of the invention, the combustionretarding material may comprise 5-60 wt % (calculated on a dry weightbasis) plant material and/or tobacco material and/or nicotine and/ortobacco extract.

In some cases, there may be no nicotine in the combustion retardingmaterial other than that which is provided from the tobacco material orthe tobacco extract.

In some embodiments the combustion retarding material comprises notobacco material but does comprise nicotine. In some such cases, thecombustion retarding material may comprise from about 1 wt %, 2 wt %, 3wt % or 4 wt % to about 20 wt %, 18 wt %, 15 wt % or 12 wt % (calculatedon a dry weight basis) nicotine. For example, the combustion retardingmaterial may comprise 1-20 wt %, 2-18 wt % or 3-12 wt % nicotine.

In some embodiments, the combustion retarding material comprises afiller. In some embodiments, the filler is included in the amorphoussolid material.

In some embodiments, the combustion retarding material comprises lessthan 60 wt % of a filler, such as from 1 wt % to 60 wt %, or 5 wt % to50 wt %, or 5 wt % to 30 wt %, or 10 Wt % to 20 wt %.

In other embodiments, the combustion retarding material comprises lessthan 20 wt %, suitably less than 10 wt % or less than 5 wt % of afiller. In some cases, the amorphous solid material comprises less than1 wt % of a filler, and in some cases, comprises no filler.

The filler, if present, may comprise one or more inorganic fillermaterials in addition to the combustion retarding salt(s), such ascalcium carbonate, perlite, vermiculite, diatomaceous earth, colloidalsilica, magnesium oxide, magnesium sulphate, magnesium carbonate, andsuitable inorganic sorbents, such as molecular sieves. The filler maycomprise one or more organic filler materials such as wood pulp,cellulose and cellulose derivatives. In particular cases, the combustionretarding material comprises no calcium carbonate such as chalk.

In particular embodiments which include filler, the filler is fibrous.For example, the filler may be a fibrous organic filler material such aswood pulp, hemp fiber, cellulose or cellulose derivatives. Withoutwishing to be bound by theory, it is believed that including fibrousfiller in the combustion retarding material may increase the tensilestrength of the material.

In some embodiments, the combustion retarding material does not comprisetobacco fibers.

In some examples, such as where the combustion retarding materialcomprises a filler, combustion retarding material may have a tensilestrength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, oraround 800 N/m. Such tensile strengths may be particularly suitable forembodiments wherein the combustion retarding material is included in anaerosol-generating article as a rolled sheet, suitably in the form of atube or a rod.

Consumables

A consumable is an article comprising aerosol-generating material, partor all of which is intended to be consumed during use by a user. Aconsumable may comprise one or more other components, such as anaerosol-generating material storage area, an aerosol-generating materialtransfer component, an aerosol generation area, a housing, a wrapper, amouthpiece, a filter and/or an aerosol-modifying agent. A consumable mayalso comprise an aerosol generator, such as a heater, that emits heat tocause the aerosol-generating material to generate aerosol in use. Theheater may, for example, comprise combustible material, a materialheatable by electrical conduction, or a susceptor. The consumable may beany shape or size that is appropriate to the smoking device. In apreferred embodiment of the invention, the consumable is a rod shape.

In the present invention, the consumable comprises a combustionretarding material as disclosed herein. In some territories, it isnecessary for the consumable to resist combustion and this may beenhanced by inclusion of the combustion retarding material.

In some embodiments, the inclusion of the combustion retarding materialin the consumable means that it is not necessary to include a foil inthe consumable. Consumables can include a metal foil, such as aluminiumfoil, as part of the wrapper surrounding the aerosol-generating materialto retard or prevent combustion.

In some embodiments, the combustion retarding material surrounds atleast some of the aerosol-generating material. For example, a wrappersurrounding the aerosol-generating material may comprise or consist of acombustion retarding material. The combustion retarding material may bein the form of a sheet. One or more layers of the combustion retardingmaterial may circumscribe the aerosol-generating material.

In some embodiments, the combustion retarding material surrounds all ofthe aerosol-generating material. Where the aerosol-generating materialis provided in the form of a rod, the combustion retarding material notonly circumscribes the length of the rod of aerosol-generating materialbut also encloses the end of the rod. This may be in the form of thesheet being folded or otherwise extended over the end of the rod, or aplug of the combustion retarding material being inserted into the end ofthe rod. This will prevent the aerosol-generating material combusting ifan attempt is made to light the consumable like a cigarette.

As described herein, the rod of aerosol-generating material may have afirst end and a second end. In use, the rod has a downstream end,usually connected to or comprising a mouthpiece and/or filter, and anupstream end, also referred to as a distal end.

In other embodiments, the combustion retarding material is providedlocally, for example, at the distal end of a rod of aerosol-generatingmaterial, with little or no combustion retarding material provided inother parts of the consumable. In some embodiments, the combustionretarding material is provided in greater concentration at a locationproximal to the distal end. In some embodiments, the combustionretarding material is provided exclusively at a location proximal to thedistal end. The area in which the combustion retarding material isprovided may be at most about 5%, at most about 10%, at most about 20%,at most about 30%, at most about 40%, at most about 50%, or at mostabout 60% of the rod from the distal end. In some embodiments thecombustion retarding material is disposed at the distal end of the rodin the form of a shredded sheet. In some embodiments in which thecombustion retarding material is shredded, said combustion retardingmaterial may be interspersed, mixed or otherwise combined with theaerosol-generating material. Alternatively, the shredded combustionretarding material may circumscribe the aerosol-generating material. Inother embodiments, the shredded combustion retarding material is notmixed with the aerosol-generating material, and may be in the form of aplug. The shredded format of the combustion retarding material has theadvantage that this is well suited to being incorporated into the rod.

In some embodiments where the combustion retarding material is disposedat the distal end of the rod, the combustion retarding material may bein the form of a gathered sheet. In some embodiments the gathered sheetis in the form of a plug. The gathered sheet format has the advantagethat travel of salt up the rod is reduced. A plug of combustionretarding material may also be formed as a solid mass comprising acombustion retarding salt and an amorphous solid material.

In some embodiments, a portion of the aerosol-generating material, suchas tobacco, may be replaced with the combustion retarding material. Insome embodiments, between about 5% to about 15%, or about 8% to about12% of the weight of the aerosol-generating material may be replacedwith the combustion retarding material. The combustion retardingmaterial may be in the form of a plug. This embodiment enjoys theadvantage of preventing the aerosol-generating material combusting if anattempt is made to light the consumable like a cigarette, whilstmaintaining the total size of the consumable or rod. This isparticularly beneficial when the rod is used as consumable in anaerosol-generating device and can be swapped with alternativeconsumable(s) already in production.

In some embodiments, the consumable may comprise at least oneventilation area arranged to allow external air to flow into thearticle. The ventilation area may comprise one or more ventilationapertures or perforations cut into the wrapper to allow ambient air tobe drawn into the article. This will influence pressure drop and canenhance the user's experience of the flavor properties of the aerosolgenerating material. The location of these vents and/or perforations maybe between about 0.5 mm to about 10 mm, between about 1 mm to about 4 mmor between about 4 mm to about 8 mm from the distal end of the rod. Thevents and/or perforations may be of any suitable size and/or number toadapt the flow-through of air. The size, number and location on thewrapper of the vents and/or perforations may be selected to provide theappropriate flow through of air. For example, more numerous and largervents and/or perforations may introduce more air into the rod, increasethe flow-through of air and thus provide the appropriate pressure drop.

In other embodiments, the combustion retarding material is mixed withthe aerosol-generating material. In such embodiments, the combustionretarding material may be in the form of a shredded or cut sheet, mixedwith the aerosol-generating material. The presence of the combustionretarding material distributed within the aerosol-generating materialcan reduce the tendency of the aerosol-generating material to combustwhen exposed to high temperatures and/or a flame.

In exemplary embodiments, the consumable comprises a blend ofaerosol-generating material and combustion retarding material. Forexample, the blend comprises aerosol-generating material in an amountfrom 50% to 98%, for instance from 80% to 95%, wherein theaerosol-generating material is for instance cut rag tobacco, andshredded amorphous solid material in an amount from 2% to 50%, forinstance from 5% to 20%.

In some embodiments, even mixing of the aerosol-generating material andthe combustion retarding material can be achieved when the combustionretarding material in sheet form is shredded. Preferably the cut widthof the shredded combustion retarding material is between 0.75 mm and 2mm, for instance between 1 mm and 1.5 mm. The strands of combustionretarding material formed by shredding may be cut width-wise, forexample in a cross-cut type shredding process, to define a cut lengthfor the shredded combustion retarding material, in addition to a cutwidth. The cut length of the shredded combustion retarding material ispreferably at least 5 mm, for instance at least 10 mm, or at least 20mm. The cut length of the shredded combustion retarding material can beless than 60 mm, less than 50 mm, or less than 40 mm. In someembodiments, to achieve even mixing of the shredded combustion retardingmaterial with cut rag tobacco, the cut length of the shredded acombustion retarding material is preferably non-uniform. Althoughreferred to as cut length, the length of the shreds or strips ofcombustion retarding material can alternatively or additionally bedictated by a dimension of the material determined during itsmanufacture, for instance the width of a sheet of the material asmanufactured.

In some embodiments, the aerosol-generating material included in theconsumable comprises one or more active substances and/or flavors. Insome embodiments, this material includes tobacco or other plant derivedmaterial. When this aerosol-generating material includes tobacco,heating this material releases volatile tobacco components includingnicotine and flavor or aroma compounds.

In some embodiments, the aerosol-generating material comprises aplant-based material, such as tobacco material. As used herein, the term“tobacco material” refers to any material comprising tobacco orderivatives or substitutes thereof. The term “tobacco material” mayinclude one or more of tobacco, tobacco derivatives, expanded tobacco,reconstituted tobacco or tobacco substitutes. The tobacco material maycomprise one or more of ground tobacco, tobacco fiber, cut tobacco,extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobaccoand/or tobacco extract.

In some embodiments, the plant material is tobacco material and may beprovided in the form of cut rag tobacco. The cut rag tobacco can have acut width of at least 15 cuts per inch (about 5.9 cuts per cm,equivalent to a cut width of about 1.7 mm). Preferably, the cut ragtobacco has a cut width of at least 18 cuts per inch (about 7.1 cuts percm, equivalent to a cut width of about 1.4 mm), more preferably at least20 cuts per inch (about 7.9 cuts per cm, equivalent to a cut width ofabout 1.27 mm). In one example, the cut rag tobacco has a cut width of22 cuts per inch (about 8.7 cuts per cm, equivalent to a cut width ofabout 1.15 mm). Preferably, the cut rag tobacco has a cut width at orbelow 40 cuts per inch (about 15.7 cuts per cm, equivalent to a cutwidth of about 0.64 mm). Cut widths between 0.5 mm and 2.0 mm, forinstance between 0.6 and 1.7 mm or between 0.6 mm and 1.5 mm, have beenfound to result in tobacco material which is preferably in terms ofsurface area to volume ratio, particularly when heated, and the overalldensity and pressure drop of the rod of aerosol-generating material. Thecut rag tobacco can be formed from a mixture of forms of tobaccomaterial, for instance a mixture of one or more of paper reconstitutedtobacco, leaf tobacco, extruded tobacco and bandcast tobacco. Preferablythe tobacco material comprises paper reconstituted tobacco or a mixtureof paper reconstituted tobacco and leaf tobacco.

The plant material, such as tobacco material, may have any suitablethickness. The plant material, such as tobacco material, may have athickness of at least about 0.145 mm, for instance at least about 0.15mm, or at least about 0.16 mm. The plant material may have a maximumthickness of about 0.25 mm, for instance the thickness of the plantmaterial may be less than about 0.22 mm, or less than about 0.2 mm. Insome embodiments, the plant material may have an average thickness inthe range 0.175 mm to 0.195 mm. Such thicknesses may be particularlysuitable where the plant material is a reconstituted tobacco material.

The tobacco material can comprise reconstituted tobacco material havinga density of less than about 700 mg/cc, for instance paper reconstitutedtobacco material. For instance, the aerosol-generating materialcomprises reconstituted tobacco material having a density of less thanabout 600 mg/cc. Alternatively or in addition, the aerosol-generatingmaterial can comprise reconstituted tobacco material having a density ofat least 350 mg/cc.

In some embodiments, the aerosol-generating material contains a fillercomponent. The filler component is generally a non-tobacco component,that is, a component that does not include ingredients originating fromtobacco. The filler component may be a non-tobacco fiber such as woodfiber or pulp or wheat fiber. The filler component may also be aninorganic material such as chalk, perlite, vermiculite, diatomaceousearth, colloidal silica, magnesium oxide, magnesium sulphate, magnesiumcarbonate. The filler component may also be a non-tobacco cast materialor a non-tobacco extruded material. The filler component may be presentin an amount of 0 to 20% by weight of the tobacco material, or in anamount of from 1 to 10% by weight of the composition. In someembodiments, the filler component is absent.

In some embodiments, the aerosol-generating material contains anaerosol-former material.

In some embodiments, the aerosol-former material included with the plantor tobacco material may be glycerol, propylene glycol, or a mixture ofglycerol and propylene glycol. Glycerol may be present in an amount offrom 10 to 20% by weight of the tobacco material, for example 13 to 16%by weight of the composition, or about 14% or 15% by weight of thecomposition. Propylene glycol, if present, may be present in an amountof from 0.1 to 15% by weight of the composition.

In some embodiments in which the plant material is a tobacco material,the tobacco material can contain between 10% and 90% by weight tobaccoleaf, wherein the aerosol-former material is provided in an amount of upto about 10% by weight of the leaf tobacco. To achieve an overall levelof aerosol-former material between 10% and 20% by weight of the tobaccomaterial, it has been advantageously found that this can be added inhigher weight percentages to the another component of the tobaccomaterial, such as reconstituted tobacco material.

The tobacco material described herein contains nicotine. The nicotinecontent is from 0.5 to 1.75% by weight of the tobacco material, and maybe, for example, from 0.8 to 1.5% by weight of the tobacco material.Additionally or alternatively, the tobacco material contains between 10%and 90% by weight tobacco leaf having a nicotine content of greater than1.5% by weight of the tobacco leaf. It has been advantageously foundthat using a tobacco leaf with nicotine content higher than 1.5% incombination with a lower nicotine base material, such as paperreconstituted tobacco, provides a tobacco material with an appropriatenicotine level but better sensory performance than the use of paperreconstituted tobacco alone. The tobacco leaf, for instance cut ragtobacco, can, for instance, have a nicotine content of between 1.5% and5% by weight of the tobacco leaf.

The plant or tobacco material described herein can contain an aerosolmodifying agent, such as any of the flavors described herein. In oneembodiment, the tobacco material contains menthol, forming a mentholatedarticle. The tobacco material can comprise from 3 mg to 20 mg ofmenthol, preferably between 5 mg and 18 mg and more preferably between 8mg and 16 mg of menthol. In the present example, the tobacco materialcomprises 16 mg of menthol. The tobacco material can contain between 2%and 8% by weight of menthol, preferably between 3% and 7% by weight ofmenthol and more preferably between 4% and 5.5% by weight of menthol. Inone embodiment, the tobacco material includes 4.7% by weight of menthol.Such high levels of menthol loading can be achieved using a highpercentage of reconstituted tobacco material, for instance greater than50% of the tobacco material by weight. Alternatively or additionally, ahigher level of menthol loading that can be achieved by incorporation ofthe menthol in an aerosol-generating material comprising an aerosolforming agent and one or more binder and/or cross-linker

In an embodiment, the tobacco material comprises the tobacco componentas defined herein and the aerosol-former material as defined herein. Inan embodiment, the tobacco material consists essentially of the tobaccocomponent as defined herein and the aerosol-former material as definedherein. In an embodiment, the tobacco material consists of the tobaccocomponent as defined herein and the aerosol-former material as definedherein.

Paper reconstituted tobacco may be present in the tobacco component ofthe tobacco material described herein in an amount of from 10% to 100%by weight of the tobacco component. In embodiments, the paperreconstituted tobacco is present in an amount of from 10% to 80% byweight, or 20% to 70% by weight, of the tobacco component. In a furtherembodiment, the tobacco component consists essentially of, or consistsof, paper reconstituted tobacco. In preferred embodiments, leaf tobaccois present in the tobacco component of the tobacco material in an amountof from at least 10% by weight of the tobacco component. For instance,leaf tobacco can be present in an amount of at least 10% by weight ofthe tobacco component, while the remainder of the tobacco componentcomprises paper reconstituted tobacco, bandcast reconstituted tobacco,or a combination of bandcast reconstituted tobacco and another form oftobacco such as tobacco granules. Suitably, leaf tobacco can be presentin an amount up to 40% or 60% of the tobacco material, while theremainder of the tobacco component comprises paper reconstitutedtobacco, bandcast reconstituted tobacco, or a combination of bandcastreconstituted tobacco and another form of tobacco such as tobaccogranules.

Paper reconstituted tobacco refers to tobacco material formed by aprocess in which tobacco feedstock is extracted with a solvent to affordan extract of solubles and a residue comprising fibrous material, andthen the extract (usually after concentration, and optionally afterfurther processing) is recombined with fibrous material from the residue(usually after refining of the fibrous material, and optionally with theaddition of a portion of non-tobacco fibers) by deposition of theextract onto the fibrous material. The process of recombinationresembles the process for making paper.

The paper reconstituted tobacco may be any type of paper reconstitutedtobacco that is known in the art. In a particular embodiment, the paperreconstituted tobacco is made from a feedstock comprising one or more oftobacco strips, tobacco stems, and whole leaf tobacco. In a furtherembodiment, the paper reconstituted tobacco is made from a feedstockconsisting of tobacco strips and/or whole leaf tobacco, and tobaccostems. However, in other embodiments, scraps, fines and winnowings canalternatively or additionally be employed in the feedstock.

The paper reconstituted tobacco for use in the tobacco materialdescribed herein may be prepared by methods which are known to thoseskilled in the art for preparing paper reconstituted tobacco.

The density of the tobacco material has an impact on the speed at whichheat conducts through the material, with lower densities, for instancethose below 700 mg/cc, conducting heat more slowly through the material,and therefore enabling a more sustained release of aerosol.

In the figures described herein, like reference numerals are used toillustrate equivalent features, articles or components.

FIG. 1 is a side-on cross sectional view of a consumable or article 1for use in an aerosol delivery system.

The article 1 comprises a mouthpiece segment 2, and an aerosolgenerating segment 3.

The aerosol generating segment 3 is in the form of a cylindrical rod andcomprises an aerosol-generating material 4 comprising cut ragreconstituted tobacco. The aerosol-generating material can be any of thematerials discussed herein.

Although described above in rod form, the aerosol generating segment 3can be provided in other forms, for instance a plug, pouch, or packet ofmaterial within an article.

The mouthpiece segment 2, in the illustrated embodiment, includes a bodyof material 5 such as a fibrous or filamentary tow.

The rod-shaped consumable 1 further comprises a wrapper 6 circumscribingthe mouthpiece segment 2 and aerosol generating segment 3. The wrapper 6comprises a sheet of combustion retarding material as described herein.In the illustrated example, the combustion retarding material is a sheetof amorphous solid material comprising sodium chloride.

FIG. 2 is a side-on cross sectional view of an alternative embodiment ofa consumable or article 1 for use in an aerosol delivery system.

In this alternative embodiment, the article 1 again comprises amouthpiece segment 2, and an aerosol generating segment 3. The aerosolgenerating segment 3 comprises a blend 7 of aerosol-generating materialand combustion retarding material.

The rod-shaped consumable 1 further comprises a wrapper 8 circumscribingthe mouthpiece segment 2 and aerosol generating segment 3. The wrapper 8comprises a sheet of paper.

Non-Combustible Aerosol Provision Systems

According to the present disclosure, a “non-combustible” aerosolprovision system is one where a constituent aerosol-generating materialof the aerosol provision system (or component thereof) is not combustedor burned in order to facilitate delivery of at least one substance to auser.

In some embodiments, the delivery system is a non-combustible aerosolprovision system, such as a powered non-combustible aerosol provisionsystem.

In some embodiments, the non-combustible aerosol provision system is anelectronic cigarette, also known as a vaping device or electronicnicotine delivery system (END), although it is noted that the presenceof nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is anaerosol-generating material heating system, also known as aheat-not-burn system. An example of such a system is a tobacco heatingsystem.

In some embodiments, the non-combustible aerosol provision system is ahybrid system to generate aerosol using a combination ofaerosol-generating materials, one or a plurality of which may be heated.Each of the aerosol-generating materials may be, for example, in theform of a solid, liquid or gel and may or may not contain nicotine.

In some embodiments, the hybrid system comprises a liquid or gelaerosol-generating material and a solid aerosol-generating material. Thesolid aerosol-generating material may comprise, for example, tobacco ora non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise anon-combustible aerosol provision device and a consumable for use withthe non-combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprisingaerosol-generating material and configured to be used withnon-combustible aerosol provision devices. These consumables aresometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, suchas a non-combustible aerosol provision device thereof, may comprise apower source and a controller. The power source may, for example, be anelectric power source or an exothermic power source. In someembodiments, the exothermic power source comprises a carbon substratewhich may be energized so as to distribute power in the form of heat toan aerosol-generating material or to a heat transfer material inproximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system maycomprise an area for receiving the consumable, an aerosol generator, anaerosol generation area, a housing, a mouthpiece, a filter and/or anaerosol-modifying agent.

FIG. 3 shows an example of a non-combustible aerosol provision device100 for generating aerosol from an aerosol-generating medium/materialsuch as the aerosol-generating material of a consumable 110, asdescribed herein. In broad outline, the device 100 may be used to heat areplaceable article 110 comprising the aerosol-generating medium, forinstance an article 1 as illustrated in any one of FIG. 1 or 2 or asdescribed elsewhere herein, to generate an aerosol or other inhalablemedium which is inhaled by a user of the device 100. The device 100 andreplaceable article 110 together form a system.

The device 100 comprises a housing 102 (in the form of an outer cover)which surrounds and houses various components of the device 100. Thedevice 100 has an opening 104 in one end, through which the article 110may be inserted for heating by a heating assembly. In use, the article110 may be fully or partially inserted into the heating assembly whereit may be heated by one or more components of the heater assembly.

The device 100 of this example comprises a first end member 106 whichcomprises a lid 108 which is moveable relative to the first end member106 to close the opening 104 when no article 110 is in place. In FIG. 3, the lid 108 is shown in an open configuration, however the lid 108 maymove into a closed configuration. For example, a user may cause the lid108 to slide in the direction of arrow “B”.

The device 100 may also include a user-operable control element 112,such as a button or switch, which operates the device 100 when pressed.For example, a user may turn on the device 100 by operating the switch112.

The device 100 may also comprise an electrical component, such as asocket/port 114, which can receive a cable to charge a battery of thedevice 100. For example, the socket 114 may be a charging port, such asa USB charging port.

Method of Manufacture

In some embodiments, the combustion retarding salt is incorporated intoor added to the amorphous solid material dissolved in a solvent orliquid carrier. In some embodiments, the combustion retarding salt is asuspension in a liquid carrier. The solvent or liquid carrier may be anaqueous or organic liquid, and may be polar or non-polar depending onits suitable application. The liquid carrier or precursor solvent may beadvantageously selected to be volatile, so that the carrier liquid orsolvent may be removed to leave the combustion retarding salt in or onthe amorphous solid material.

In some embodiments, the solvent or liquid carrier comprises a mixtureof water and glycerol.

Example

Consumables with a range of different wrappers surrounding a rod ofaerosol-generating material were prepared and their combustioncharacteristic compared.

Consumables comprising cut rag aerosol-generating material wereprepared, using a variety of different wrappers.

The first wrapper used was paper, namely 24 GSM (grammes per squaremetre) paper with a porosity of 75 CU (Coresta units).

Further wrappers used were 32 GSM and 64 GSM Delfort papers.

A further wrapper used was laminated aluminium foil comprising 6.3 μmthickness lacquered aluminium foil laminated with 23.5 GSM paper with 37μm thickness.

Finally, a combustion retarding material according to the presentdisclosure was used, formed from a slurry having the following make up:

-   -   43 g alginate (2.7%)    -   100 g sodium chloride (6.3%)    -   50 g glycerol (3.1%)    -   1400 ml water (87.9%)

The consumables were hand made, by inserting the combustion retardingsheet as an inner wrapper, and then filling the rod with tobacco.

For testing, the consumables were lit in the manner of a combustiblecigarette and attempts were made to smoke them by puffing. The greaterthe combustion resistance of the wrapper materials, the less of theconsumable was combusted.

Tests showed that the amorphous solid material comprising sodiumchloride resisting combustion well and performed similarly to the knowncombustion retardant foil and Delfort papers.

In addition, further combustion retarding material according to thepresent disclosure was used, formed from a slurry having the followingmake up:

21.5 g alginate 21.5 g wood pulp 120 g sodium chloride 30 g glycerol1400 ml water

The slurry was dried in an oven to form a sheet. The sheets that wereobtained did not combust when exposed to a naked flame from a lighter.

The various embodiments described herein are presented only to assist inunderstanding and teaching the claimed features. These embodiments areprovided as a representative sample of embodiments only, and are notexhaustive and/or exclusive. It is to be understood that advantages,embodiments, examples, functions, features, structures, and/or otheraspects described herein are not to be considered limitations on thescope of the invention as defined by the claims or limitations onequivalents to the claims, and that other embodiments may be utilizedand modifications may be made without departing from the scope of theclaimed invention. Various embodiments of the invention may suitablycomprise, consist of, or consist essentially of, appropriatecombinations of the disclosed elements, components, features, parts,steps, means, etc., other than those specifically described herein. Inaddition, this disclosure may include other inventions not presentlyclaimed, but which may be claimed in future.

1. A material comprising a combustion retarding salt and an amorphoussolid material.
 2. The material as claimed in claim 1, wherein thecombustion retarding salt is an alkali metal salt, optionally selectedfrom the group consisting of: sodium chloride, potassium chloride,sodium bromide, potassium bromide, and combinations thereof.
 3. Thematerial as claimed in claim 1, wherein the combustion retarding salt isincorporated in the amorphous solid material.
 4. The material as claimedin claim 1, wherein the combustion retarding salt is applied to theamorphous solid material.
 5. The material as claimed in claim 1, whereinthe material comprises from about 3 wt % to about 60 wt % combustionretarding salt (dry weight basis).
 6. A consumable comprising thematerial as claimed in claim
 1. 7. The consumable as claimed in claim 6,wherein the consumable further comprises an aerosol-generating material.8. The consumable as claimed in claim 7, wherein the material at leastpartially surrounds the aerosol-generating material.
 9. The consumableas claimed in claim 6, wherein the consumable further comprises awrapper.
 10. The consumable as claimed in claim 7, wherein the materialis distributed within the aerosol-generating material.
 11. Theconsumable as claimed in claim 6, wherein the aerosol-generatingmaterial comprises tobacco material.
 12. The consumable as claimed inclaim 11, wherein the tobacco material is cut rag tobacco.
 13. Theconsumable as claimed in claim 6, wherein the consumable comprises abinder.
 14. The consumable as claimed in claim 6, wherein the consumableis rod shaped.
 15. The consumable as claimed in claim 14, wherein therod has a distal and proximal end and wherein the material is providedexclusively or in greater concentration at a location proximal to thedistal end of the rod.
 16. A non-combustible aerosol provision systemcomprising a consumable as claimed in claim
 6. 17. A method formanufacturing the material as claimed in claim 1, wherein the combustionretarding salt is incorporated into or added to the amorphous solidmaterial.
 18. The method as claimed in claim 17, wherein a solution orsuspension comprising the combustion retarding salt is applied to theamorphous solid material.
 19. The method as claimed in claim 17, whereinthe combustion retarding salt is added during the manufacture of theamorphous solid material.
 20. Use of the material as claimed in claim 1for retarding combustion of a consumable for use in a non-combustibleaerosol provision system.